Reader with swappable power/communication module

ABSTRACT

A power/communication kit for use with a reader module where the code reader module includes a reader connector and a reader housing, the power/communication kit comprising a plurality of different power/communication modules wherein each module communicates via a different communication protocol and each includes a power source and a communication component suitable for communicating via an associated communication protocol, wherein, each of the modules is securable to the reader module in a similar fashion such that any one of the power/communication modules can be swapped for any other of the power/communication modules so that the reader can be used with different communication systems.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to hand held image based ID code readersand more particularly to an assembly that includes a single imagingmodule that can be used with any of several differentpower/communication modules so that the imaging module can be used inany of several different applications.

2. Description of the Related Art

Images acquired for code reading, also known as direct part mark (“DPM”)or label-based identification, include one or more 1D (e.g., a barcode)or 2D (e.g., a Data Matrix code) symbols located on an object. The codereading process includes repeatedly introducing an object marked witheither 1D or 2D codes within a field of view of an image acquisitionsensor (e.g., CMOS camera, CCD, etc.), illuminating the codes, andacquiring images, i.e., image data, containing the codes. Each codecontains a set of predetermined patterns from which an attached dataprocessor, such as a computer, can derive useful information about theobject (e.g., serial number, type, model, price, etc.).

The handheld ID code reader can be connected to a server or remoteprocessor via a network to exchange code reading results, images, aswell as reader setup and reader status information. This connection canbe facilitated via several different interfaces. For instance, exemplaryinterface options include a tether which includes a cable and a powersource or a wireless interface that uses RF for data transition andenergy storage devices (e.g., rechargeable batteries) as a power source.When a reader is to be used generally in one area, a tethered interfacemay be employed and, where an interface is to be used in many differentand disperse locations, a wireless interface may be employed.

In addition to requiring either wireless or tethered interfaces,different systems often require different communication protocols andreader interfaces. For instance, some systems may require a reader tocommunicate via any one of RS232, Bluethooth, USB, PS2, Ethernet, RS485,etc. Here, if a reader includes an RS232 interface, that reader cannotbe used with a system that communicates via one of the other interfacetypes (e.g., USB, Ethernet, etc.). Thus, if a facility installs a newsystem that communicates via USB or some other interface type, the RS232reader could not be used in the new system. Similarly, if a reader isconfigured to communicate via a tether and Ethernet and a facilityupgrades the communication system to wireless Bluetooth, the readercannot be used with the new system.

One solution to the above problem would be to provide a reader that isequipped to communicate via any of the possible types of interfaces.While this solution would provide a versatile reader, there are severalshortcomings to this solution. First, with respect to Ergonomics, havinga high number of interfaces requires a reader to have a connector with ahigh number of contacts. A multi-interface connector can only reasonablybe placed at the bottom side of a reader handle. More contacts increasethe size of the connector and the handle size/diameter. Due to ergonomicconstraints there is a limit on handle size. In addition, more interfacecontacts would require more wires inside a tethered cable resulting inhigher cable weight and lower flexibility making it difficult to easilymove the reader. Moreover, for the majority of practical applications,only one interface is desired at a time.

With respect to power requirements, the intention of a wireless readerwith RF communication is that it operates without any cables. Thisrequires a battery to power the device. Because of the relative highpower consumption of an image based ID reader the operating time islimited by the battery capacity. This makes it necessary to have arechargeable battery. A typical interface for a tethered ID readers isRS232, which allows exchanging data serially. RS232 cannot power adevice and some kind of external power supply (e.g. wall adapter) isnecessary to power the reader. In contrast, other interfaces like PS2,USB and Ethernet (Power Over Ethernet (POE)) are capable of providingenough power for an attached reader. Some protocols, especially USB andPOE have complex power management requirements like start-up currentlimitations, power sequencing and classification, and low power mode. Anextremely complex interface assembly would be required to support all ofthe possible communication protocols currently in use.

With respect to electronics for each of the interface types, differentinterface types communicate using different signal levels and havedifferent requirements in terms of signal speed and quality.Multiplexing different interface signals to a limited number ofconnector pins would require a huge technical effort and is notpracticable in a cost and size reasonable way. In addition, electronicparts could be damaged if an error occurs and a multiplexer is set to awrong connection type. Moreover, all contacts with external connectionsmust be protected against electro static discharge (ESD). Because of thedifferent signal levels and high speed requirements associated withdifferent interface types, a one for all protection circuit is notoptimal for all interface types.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a tethered reader according to oneembodiment of the present invention:

FIG. 2 is a perspective view of the reader of FIG. 1 with a readermodule in phantom and a power/communication module in solid line;

FIG. 3 is a perspective view of the reader in FIG. 1 where thepower/communication module has been disconnected;

FIG. 4 is a schematic showing the components that from thepower/communication module of FIG. 3;

FIG. 5 is similar to FIG. 1, albeit illustrating a wirelesspower/communication module in a cradle;

FIG. 6 is a view similar to the view of FIG. 2, albeit showing thewireless power/communication module of FIG. 5;

FIG. 7 is a view similar to the view in FIG. 3, albeit showing thewireless power/communication module of FIG. 5;

FIG. 8 is a view similar to the view of FIG. 4, albeit showingcomponents in an exemplary wireless power/communication module; and

FIG. 9 is a partial perspective view of the module of FIG. 7 showing aclip connector that links a battery to a PCB board; and

FIG. 10 is a partial perspective view of the module of FIG. 7 showing anend battery cap and adjacent cradle contacts.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numbers correspondto similar elements throughout the several views, a reader kit 10 a, 10b is illustrated that includes a single reader module 12 and a pluralityof different power/communication modules 14 a, 14 b (only twopower/communication modules shown). As shown, module 14 a is a tetheredmodule that includes a cable 18 for receiving power and forcommunicating data back and forth between the reader module 12 and anexternal computer 20. Module 14 b includes an antenna 22 (see FIG. 8)and a rechargeable battery 24 so that when module 14 b is secured toreader module 12, the assembly can be used in a wireless and untetheredfashion.

The general support and housing structures for each of the tethered andwireless modules is similar and therefore, that structure will only bedescribed once in the context of the tethered embodiment illustrated inFIGS. 2 and 3.

Referring specifically to FIG. 2, reader module 12 includes a housingstructure 28 that includes a barrel portion 30 and a handle portion 32.An imaging assembly (not illustrated) including an image sensor, lenses,illumination devices, a processor, a memory, etc., is located in barrelportion 30. A cavity 34 is formed in handle portion 32 where an opening(at the bottom of the handle portion) is formed that opens into thecavity 34. A reader connector 40 resides at the top end of the cavity 34and forms a receiving channel (not illustrated) for receiving apower/communication module connector 58 (see FIG. 3 or FIG. 7) when amodule 14 a or 14 b is inserted into the cavity 34.

Referring still to FIGS. 2 and 3, module 14 a includes a module supportstructure 46 in the form of an end cap that compliments the opening atthe bottom of the handle cavity 32. Although not illustrated, it iscontemplated that there will be some type of mechanical fasteningmechanism (e.g., one or more screws, a compression securement, tabs andassociated receiving holes, etc.) for securing structure 46 at the endof the cavity as shown in FIGS. 1 and 2.

Tethered Modules

Referring to FIG. 3, the exemplary tethered module 14 a includes a PCBboard 50, a board cover 52, a cable plug 54, a cable lock 56 and amodule connector 58. Although not illustrated, circuitry is mounted toboard 50. Referring also to FIG. 4, the circuitry includes anon-volatile memory 60, an interface controller 62, a protectiontermination circuit/filter 68, a cable plug 70, a power supply 64 and apower management unit 66. The cable plug 68 provides a mechanical keyingfeature that ensures that only a matching cable (e.g., USB, Ethernet,etc.) can be plugged in to the module 14 a. Alternatively, “electricalkeying” might be possible as well, but the effort compared to mechanicalkeying is higher.

Protection circuit 68 secures reader electronics against over current,over voltage, electrostatic discharge (ESD) and reverse polarity.Electro magnetic emissions (EMI) are attenuated by filter 68 and signalintegrity is ensured by adequate line termination. The interfacecontroller 62 contains the physical layer of the interface module 14 aproviding data translation and signal integrity between reader datasignals and cable interface signals. Non-volatile memory contains acommunication module ID and may also contain interface setup informationlike a MAC address. Power supply 64 is optimized for voltagescorresponding to a specific one of several different types ofpower/communication modules. In this regard, see table 1 below thatindicates specific operating parameters for different types of tetheredpower/communication modules contemplated by the present disclosure.Here, it should be appreciated that there are other tetheredcommunication protocols and that any existing or future protocol couldbe used with the present disclosure.

TABLE 1 Communication Interface Used for Power RS232 Serialcommunication Wall adapter Desktop power supply Typ. +5 . . . +12 VDCUSB HID (HID) Powered by USB host or USB serial (CDC) USB hub +5 VDC Etc. . . PS2 Keyboard Emulation Powered by Host Keyboard wedge +5 VDCEthernet Various Ethernet POE (Power over Ethernet) protocols Typ. +48VDC RS485 PROFIBUS Industrial MODBUS, etc Typ. +5 V, +24 VDC CAN CANopenIndustrial DeviceNet Typ. +5 V, +24 VDC

Some tethered power/communication modules require special powermanagement functions. For example, a USB module has a limited start-upcurrent and low power consumption in a suspend mode of operation. Asanother example, a detection process must be supported for a power overEthernet (POE) module. The power management unit 66 controls supply 64in a manner that is suitable for use with an associated type ofpower/communication module (e.g., 14 a, 14 b, etc.).

Referring again to FIG. 3, module 14 a may be any of the module typesshown in Table 1 or other types. In any case, the module connector 58and support 46 will be similar while the cable plug 70, memory 60,interface controller 62, circuitry 68, power supply 64 and managementunit 66 will be different and will depend on which type of module isused.

It should be appreciated that by swapping one module for another, thecommunication protocol, cable plug and power management can be modifiedto suit any tethered communication type.

Wireless Modules

Referring now to FIGS. 5 through 10, several of the module 14 bcomponents are similar to the components described above including thereader module 12 that forms cavity 32 and supports the reader connector40 at the top end of the cavity 32, cover 52 and connector 44. In thiscase, referring to FIG. 8, PCB board 80 includes several components thatare similar to the components described above including the non-volatilememory 60, interface controller 62, protection circuitry and filter 68,power management unit 66 and power supply 64. Additional circuitry inthe wireless embodiment of FIG. 8 also includes an RF chip module 90,cradle contacts 9, and battery cap sensor 94. In addition, referring toFIGS. 6 through 8, module 14 b includes a battery 24, a battery charger96 (alternatively, the charger can also be part of the cradle interface110) and an antenna 22. Referring also to FIG. 9, positive and negative(only one shown) clips 100 are mounted to the PCB board 50 and arereceived in channels (e.g., 102) formed in opposite sides of the battery24 to make contact with positive and negative battery terminals and tohelp hold the battery in an installed position.

Referring again to FIG. 8, RF chip/module 90 may be a WiFi module, aBluetooth module or any other RF technology that facilitates wirelesscommunication with an external computing device (e.g., 20 in FIG. 1).Antenna 22 is optimized for the communication protocol associated withRF chip/module. Non-volatile memory 60 contains a communication moduleID and may also contain Interface setup information like a MAC address,Bluetooth ID and speed rate settings for RF communication and a cradleinterface 110 (se FIG. 5).

Serial interface controller 62 is a “non RF” interface (e.g. RS232, USB,I2C, SPI) that enables communication when a reader including module 14 bis placed in a cradle so that contacts 92 make contact with cradlecontacts (not illustrated). Thus, cradle communication as opposed towireless communication may be supported by at least some kitsubassemblies. The contacts 92 (see also FIG. 10) may be used for bothpower (e.g., for charging the battery 24) and data transmission when themodule 14 a is received in cradle 110. Protection circuit/filter 68protects the communication module and the base station againstelectrostatic discharge (ESD) and over current/over voltage. Filters 68reduce electro magnetic emissions (EMI).

Referring to FIG. 10, module 14 b includes a support structure 46 thatincludes a battery cap 120 that can be removed to replace battery 24without detaching module 14 b from reader module 12 (see again FIG. 6).Battery cap 112 is monitored adjacent a sensor (see 94 in FIG. 8) thatprovides a signal to the reader module 12 when the battery cap is beingremoved so that the reader can save internal operating data before thebattery is finally removed. Battery charger 96 is linked to battery 24and charges battery 24 when the reader is placed in a cradle 110 as inFIG. 5.

Power management unit 66 includes logic for a device On/Off function andsupports power down modes to save battery power. Power down modes may bedifferent for different RF technologies. For instance, while somewireless modules may be able to be powered down, others may need powerall the time to keep an RF link alive. Power supply 64 is optimized forbattery operating conditions.

Wireless embodiments may include a WiFi module, a Bluetooth module, awireless USB module, a ZigBee module and a non-RF wireless module (e.g.,where information is stored to nonvolatile memory and is transmitted viacradle contacts when a reader is placed into the base station cradle110.

It should be appreciated that the reader module 12 is essentiallyidentical regardless of which of the tethered or wireless modules 14 a,14 b is secured thereto and that any of the tethered or wireless modulesmay be swapped for any of the other tethered or wireless modules for usewith a single reader module. Thus, one advantage of the inventive systemis that only one version of the ID reader is required and that the powerand communication interface for the reader is easily changeable by thereader user. In addition, any tethered reader type has only a singlecable including power and communication cables. Moreover, the system isopen for use with different module types that use future interfacestandards. Furthermore, the system described optimizes power supply andhas protection circuitry that is optimized for specific protocols. Inaddition, interface setup information can be stored to the module memoryto facilitate swapping a reader from one power/communication module toanother without loosing communication parameters. In addition, salespeople only require a single reader with a set of physically small sizeconnection modules to demonstrate all interface options. Moreover,software developers and test engineers can do their work with only asingle reader and a set of power/communication modules. Furthermore,defective power/communication modules can easily be repaired by swappingin a different module of the same type. In addition, the swappabledesign simplifies component stocking. Instead of stocking multiplereader types, the modular concept enables stocking of a kit including asingle type of reader module and multiple different types ofpower/communication modules.

The foregoing description was primarily directed to a preferredembodiment of the invention. Although some attention was given tovarious alternatives within the scope of the invention, it isanticipated that one skilled in the art will likely realize additionalalternatives that are now apparent from disclosure of embodiments of theinvention. Accordingly, the scope of the invention should be determinedfrom the following claims and not limited by the above disclosure.

To apprise the public of the scope of this invention, the followingclaims are made:

What is claimed is:
 1. A power/communication module for use with areader module where the code reader module includes a reader connectorand a reader housing, the power/communication module comprising: apower/communication module connector for releasable connection to thereader connector; a power supply linked to the module connector forproviding power to the reader module via the reader connector; acommunication component for communicating with an external computingdevice; and an interface controller linked between the module connectorand the communication component and programmed to translate data betweenthe communication component and the reader module; a module supportstructure securable to the reader housing and configured to support allof the module connector, power supply, communication component andinterface controller such that the module support structure andcomponents supported thereby are removable from the reader module as asingle assembly.